U.S. patent application number 10/567509 was filed with the patent office on 2009-01-15 for electric power connection for electrically assisted turbocharger.
This patent application is currently assigned to Honeywell International, Inc.. Invention is credited to Phillipe Noelle.
Application Number | 20090016911 10/567509 |
Document ID | / |
Family ID | 34259116 |
Filed Date | 2009-01-15 |
United States Patent
Application |
20090016911 |
Kind Code |
A1 |
Noelle; Phillipe |
January 15, 2009 |
Electric Power Connection For Electrically Assisted
Turbocharger
Abstract
A turbocharger comprises a compressor housing for accommodating
a compressor wheel drivable by an electric motor and an electric
motor for driving a compressor wheel accommodated in a compressor
housing, said electric motor being supplied with electric power
through at least one motor plug connector. The turbocharger further
comprises a turbine housing for accommodating a turbine wheel
driven by exhaust gas, a center housing for accommodating a shaft
and the electric motor, the shaft serving as a rotor of the
electric motor and extending from the turbine wheel through a
journal bearing and the electric motor to the compressor wheel. The
compressor wheel is driven by the turbine wheel via the shaft and
can additionally be driven by the electric motor, wherein the
compressor housing further comprises at least one main power plug
connector connectable to an electric power source and at least one
housing plug connector electrically connected to a respective one
of the main power plug connector for supplying said electric motor
with electric power. The said housing plug connector is disposed on
an axial side of said compressor housing, facing said electric
motor, and said motor plug connector is disposed on an axial side
of said electric motor, facing said compressor housing.
Inventors: |
Noelle; Phillipe; (Vincey,
FR) |
Correspondence
Address: |
HONEYWELL TURBO TECHNOLOGIES
23326 HAWTHORNE BOULEVARD, SUITE #200
TORRANCE
CA
90505
US
|
Assignee: |
Honeywell International,
Inc.
Morristown
NJ
|
Family ID: |
34259116 |
Appl. No.: |
10/567509 |
Filed: |
September 5, 2003 |
PCT Filed: |
September 5, 2003 |
PCT NO: |
PCT/EP2003/009877 |
371 Date: |
February 7, 2006 |
Current U.S.
Class: |
417/407 |
Current CPC
Class: |
Y02T 10/144 20130101;
F02B 39/10 20130101; Y02T 10/12 20130101; F01D 15/10 20130101; F05D
2220/40 20130101; F02B 37/10 20130101 |
Class at
Publication: |
417/407 |
International
Class: |
F04B 17/06 20060101
F04B017/06 |
Claims
1. Electric motor for driving a compressor wheel accommodated in a
compressor housing, said electric motor being supplied with
electric power through at least one motor plug connector,
characterized in that said motor plug connector is disposed on an
axial side of said electric motor, facing said compressor
housing.
2. Electric motor according to claim 1, wherein said motor plug
connector is formed as a male plug connector.
3. Electric motor according to claim 1, wherein said motor plug
connector is formed as a female plug connector.
4. Electric motor according to claim 1, wherein a plurality of said
motor plug connectors is arranged at equal intervals on a circle
around the axis of the electric motor.
5. Electric motor according to claim 1, wherein the motor plug
connectors are blade-shaped and extend in an axial direction of the
electric motor.
6. Electric motor according to claim 5, wherein the motor plug
connectors are slanted with respect to the radial direction of the
electric motor.
7. Electric motor according to claim 5, wherein the motor plug
connectors are perpendicular to the radial direction of the
electric motor.
8. Electric motor according to any of claims 5 to 7, provided with
six motor plug connectors each of which is a connector to a lead
wire.
9. Electric motor according to any of the preceding claims,
accommodated in an electric motor cartridge, wherein said at least
one motor plug connector penetrates the electric motor
cartridge.
10. Compressor housing for accommodating a compressor wheel
drivable by an electric motor, characterized in that said
compressor housing comprises at least one main power plug connector
connectable to an electric power source; and at least one housing
plug connector electrically connected to a respective one of the at
least one main power plug connector for supplying said electric
motor with electric power, wherein said housing plug connector is
disposed on an axial side of said compressor housing, facing said
electric motor.
11. Compressor housing according to claim 10, wherein said housing
plug connector is formed as a female plug connector.
12. Compressor housing according to claim 10, wherein said housing
plug connector is formed as a male plug connector.
13. Compressor housing according to claim 11 or 12, wherein said at
least one main power plug connector is connected to said at least
one housing plug connector via a printed circuit board.
14. Compressor housing according to claim 10, wherein a plurality
of said housing plug connectors is arranged by equal intervals on a
circle around the axis of the compressor housing.
15. Compressor housing according to claim 14, wherein a plurality
of main power plug connectors is arranged as a bundle on the side
of the printed circuit board opposite to the side where the housing
plug connectors are disposed.
16. Compressor housing according to claim 15, wherein the housing
plug connectors are slot-shaped and extend in an axial direction of
the compressor housing.
17. Compressor housing according to claim 16, wherein housing plug
connectors are slanted with respect to the radial direction of the
compressor housing.
18. Compressor housing according to claim 16, wherein housing plug
connectors are perpendicular to the radial direction of the
compressor housing.
19. Compressor housing according to any of claims 16 to 18,
provided with six housing plug connectors each of which is a
connector to a lead wire.
20. Compressor housing according to any of claims 15 to 19, wherein
the printed circuit board is provided with at least one track for
connecting each of the main power plug connectors to the respective
one of the housing plug connectors.
21. Compressor housing according to claim 20, wherein the printed
circuit board is provided with three tracks.
22. Compressor housing according to any of claims 13 to 21, wherein
the printed circuit board is circular and disposed coaxial to a
volute of the compressor housing between said volute and the
compressor wheel.
23. Turbocharger comprising an electric motor for driving a
compressor wheel accommodated in a compressor housing, said
electric motor being supplied with electric power through at least
one motor plug connector, further comprising a turbine housing for
accommodating a turbine wheel driven by exhaust gas; a center
housing for accommodating a shaft and the electric motor, the shaft
serving as a rotor of the electric motor and extending from the
turbine wheel through a journal bearing and the electric motor to
the compressor wheel; wherein the compressor wheel is driven by the
turbine wheel via the shaft and can additionally be driven by the
electric motor, characterized in that said motor plug connector is
disposed on an axial side of said electric motor, facing said
compressor housing.
24. Turbocharger according to claim 23, wherein said motor plug
connector is formed as a male plug connector.
25. Turbocharger according to claim 23, wherein said motor plug
connector is formed as a female plug connector.
26. Turbocharger according to claim 23, wherein a plurality of said
motor plug connectors is arranged at equal intervals on a circle
around the axis of the electric motor.
27. Turbocharger according to claim 23, wherein the motor plug
connectors are blade-shaped and extend in an axial direction of the
electric motor.
28. Turbocharger according to claim 27, wherein the motor plug
connectors are slanted with respect to the radial direction of the
electric motor.
29. Turbocharger according to claim 27, wherein the motor plug
connectors are perpendicular to the radial direction of the
electric motor.
30. Turbocharger according to any of claims 26 to 29, provided with
six motor plug connectors each of which is a connector to lead
wire.
31. Turbocharger according to any of the claims 23 to 30, wherein
the electric motor is accommodated in an electric motor cartridge,
wherein said at least one motor plug connector penetrates the
electric motor cartridge.
32. Turbocharger comprising a compressor housing for accommodating
a compressor wheel drivable by an electric motor, further
comprising a turbine housing for accommodating a turbine wheel
driven by exhaust gas; a center housing for accommodating a shaft
and the electric motor, the shaft serving as a rotor of the
electric motor and extending from the turbine wheel through a
journal bearing and the electric motor to the compressor wheel;
wherein the compressor wheel is driven by the turbine wheel via the
shaft and can additionally be driven by the electric motor,
characterized in that said compressor housing further comprises at
least one main power plug connector connectable to an electric
power source; and at least one housing plug connector electrically
connected to a respective one of the at least one main power plug
connector for supplying said electric motor with electric power,
wherein said housing plug connector is disposed on an axial side of
said compressor housing, facing said electric motor.
33. Turbocharger according to claim 32, wherein said housing plug
connector is formed as a female plug connector.
34. Turbocharger according to claim 32, wherein said housing plug
connector is formed as a male plug connector.
35. Turbocharger according to claim 33 or 34, wherein said at least
one main power plug connector is connected to said at least one
housing plug connector via a printed circuit board.
36. Turbocharger according to claim 32, wherein a plurality of said
housing plug connectors is arranged by equal intervals on a circle
around the axis of the compressor housing.
37. Turbocharger according to claim 36, wherein a plurality of main
power plug connectors is arranged as a bundle on the side of the
printed circuit board opposite to the side where the housing plug
connectors are disposed.
38. Turbocharger according to claim 37, wherein the housing plug
connectors are slot-shaped and extends in an axial direction of the
compressor housing.
39. Turbocharger according to claim 38, wherein housing plug
connectors are slanted with respect to the radial direction of the
compressor housing.
40. Turbocharger according to claim 38, wherein housing plug
connectors are perpendicular to the radial direction of the
compressor housing.
41. Turbocharger according to any of claims 38 to 40, provided with
six housing plug connectors each of which is a connector to a lead
wire.
42. Turbocharger according to any of claims 37 to 41, wherein the
printed circuit board is provided with at least one track for
connecting each of the main power plug connectors to the respective
one of the housing plug connectors.
43. Turbocharger according to claim 42, wherein the printed circuit
board is provided with three tracks.
44. Turbocharger according to any of claims 35 to 43, wherein the
printed circuit board is circular and disposed coaxial to a volute
of the compressor housing between said volute and the compressor
wheel.
45. Turbocharger comprising a compressor housing for accommodating
a compressor wheel drivable by an electric motor and an electric
motor for driving a compressor wheel accommodated in a compressor
housing, said electric motor being supplied with electric power
through at least one motor plug connector, further comprising a
turbine housing for accommodating a turbine wheel driven by exhaust
gas; a center housing for accommodating a shaft and the electric
motor, the shaft serving as a rotor of the electric motor and
extending from the turbine wheel through a journal bearing and the
electric motor to the compressor wheel; wherein the compressor
wheel is driven by the turbine wheel via the shaft and can
additionally be driven by the electric motor, characterized in that
said compressor housing further comprises at least one main power
plug connector connectable to an electric power source; and at
least one housing plug connector electrically connected to a
respective one of the main power plug connector for supplying said
electric motor with electric power, wherein said housing plug
connector is disposed on an axial side of said compressor housing,
facing said electric motor, and said motor plug connector is
disposed on an axial side of said electric motor, facing said
compressor housing.
46. Turbocharger comprising a compressor housing according to any
of claims 1 to 9 and an electric motor according to any of claims
10 to 22, further comprising a turbine housing for accommodating a
turbine wheel driven by exhaust gas; a center housing for
accommodating a shaft and the electric motor, the shaft serving as
a rotor of the electric motor and extending from the turbine wheel
through a journal bearing and the electric motor to the compressor
wheel; wherein the compressor wheel is driven by the turbine wheel
via the shaft and can additionally be driven by the electric motor.
Description
[0001] The invention relates to an electric motor and a compressor
housing both being connectable via plug connectors for power
supply, and to a turbocharger comprising the electric motor and the
compressor housing for electrically assisted compression of air for
an engine.
[0002] Turbochargers are well known and widely used in connection
with combustion engines. Exhaust gas from the engine is supplied to
and drives a turbine wheel which drives a compressor wheel. The
compressor wheel compresses air and discharges it into combustion
chambers of respective cylinders. The thus compressed air contains
a larger amount of oxygen to enhance the combustion of fuel and
thus to generate more power. However, as exhaust gas having less
energy is supplied to the turbine wheel when the rotation speed of
the engine is low, the pressure increase of the air supplied to the
combustion chambers is low. This results in a so-called "turbo-lag"
for low engine speed ranges in which an engine output is low. A
known solution for overcoming this turbo-lag is to provide an
electric motor for the turbocharger which accelerates the
compressor wheel when the rotational speed of the engine is low for
ensuring the pressure of the air supplied to the combustion
chambers.
[0003] In the international application No. PCT/EP 03/03934, there
is described a turbocharger shown in FIG. 10 having an electric
motor for assisting the rotation of a rotor. The turbocharger has a
shaft carrying a turbine wheel accommodated in a turbine housing
and a compressor wheel accommodated in a compressor housing. The
shaft is supported by a bearing accommodated in a center housing
and the electric motor is accommodated in an electric motor
cartridge inserted into the center housing and fixed by the
compressor housing. The electric motor is supplied with power
through lead wires which pass through the cartridge and through the
center housing in a substantially radial direction. As shown in
FIG. 11, this may result in an arrangement of the lead wires such
that they are exposed to sharp edges of the center housing and pass
through a cooling water cavity of the center housing. This
arrangement thus bears the risk of short circuit. Besides, the
assembly of the lead wires to the center housing is cumbersome.
[0004] Accordingly, there is a need to provide an improved power
connection for an electric motor in a turbocharger.
[0005] According to one aspect of the invention, the above need is
met with an electric motor having the features of claim 1.
Modifications of the electric motor are set forth in the subclaims
2 to 9.
[0006] According to another aspect of the invention, the above need
is met with a compressor housing having the features of claim 10.
Modifications of the compressor housing are set forth in the
subclaims 11 to 22.
[0007] According to a further aspect of the invention, the above
need is met with a turbocharger having the features of one of
claims 23, 32, 45 and 46. Modifications of the turbocharger are set
forth in the subclaims 24 to 31 and 33 to 44, respectively.
[0008] In an exemplary embodiment of the invention an electric
motor for driving a compressor wheel accommodated in a compressor
housing is supplied with electric power through at least one motor
plug connector, wherein said motor plug connector is disposed on an
axial side of said electric motor facing said compressor housing.
With this arrangement, the motor plug connector does not interfere
with a center housing into which the electric motor is inserted. A
water cavity for cooling the center housing accommodating said
electric motor can be formed according to cooling requirement
without being limited by the plug connector. This brings an
improved cooling performance. Additionally, the assembly of the
electric motor into the center housing is simplified since there is
no need of threading lead wires for the power connection of the
electric motor through one or more holes of the center housing.
[0009] Additionally, since the plug connector is disposed on the
axial side of the electric motor and does not pass the center
housing, there is no need to pass boundary conditions for the
guidance of the lead wires, e.g. like sharp edges, at which a short
circuit of the lead wires may occur.
[0010] According to exemplary embodiments of the electric motor,
the motor plug connector may be formed as a male plug connector or
as a female plug connector.
[0011] Furthermore, a plurality of said motor plug connectors can
be arranged at equal angular intervals on a circle around the axis
of the electric motor.
[0012] The motor plug connectors may be blade-shaped and may extend
in an axial direction of the electric motor. Additionally, the
motor plug connectors can be slanted with respect to the radial
direction of the electric motor. This makes it possible to arrange
the motor plug connectors with respect to the air flow into a
compressor housing volute for providing optimal fluidic
characteristics.
[0013] In an exemplary embodiment the electric motor is provided
with six motor plug connectors each of which is a connector to a
lead wire.
[0014] The electric motor may be accommodated in an electric motor
cartridge, wherein said at least one motor plug connector
penetrates the electric motor cartridge. Thus the advantages
provided by the electric motor cartridge can be combined with the
advantages obtained by the arranging the motor plug connectors on
the axial side of the electric motor which faces the axial side of
the compressor housing.
[0015] In another exemplary embodiment of the invention a
compressor housing is provided for accommodating a compressor wheel
drivable by an electric motor, wherein said compressor housing
comprises at least one main power plug connector connectable to an
electric power source and at least one housing plug connector
electrically connected to the at least one main power plug
connector for supplying said electric motor with electric power,
wherein said housing plug connector is disposed on an axial side of
said compressor housing, facing said electric motor. Such a
compressor housing makes it possible to provide power from a power
source to the electric motor of a turbocharger through the
compressor housing. Accordingly, there is no need to pass a central
housing, so that the related advantages as set forth above are
obtained. Furthermore, the main power connector is at a low
temperature area, namely at the compressor housing inlet, and the
plug connectors are also at a low temperature area, namely at the
compressor housing diffuser. Thus, an over-heating of the power
connection is prevented.
[0016] According to exemplary embodiments of the compressor housing
said main power plug connector and/or said housing plug connector
may be formed as a female plug connector or as a male plug
connector.
[0017] In the compressor housing said main power plug connector may
be connected to said housing plug connector via a printed circuit
board. Additionally, a plurality of said housing plug connectors
can be arranged at equal intervals on a circle around the axis of
the compressor housing and a plurality of said main power plug
connectors may be arranged as a bundle on the side of the printed
circuit board opposite to the side thereof where the housing plug
connectors are disposed. The use of the printed circuit board makes
it possible to easily connect the main power plug connectors to the
housing plug connectors while minimizing a short circuit risk. The
arrangement of the main power plug connectors as a bundle makes it
possible to easily connect them to a minimized main power contra
plug.
[0018] The housing plug connectors may be slot-shaped and may
extend in an axial direction of the compressor housing. The housing
plug connectors may be slanted with respect to the radial direction
of the compressor housing so as to match to the blade shaped plug
connectors.
[0019] Preferably, the compressor housing is provided with six
housing plug connectors each of which is a connector to a lead
wire.
[0020] Furthermore, the printed circuit board is provided with at
least one track for connecting each of the main power plug
connectors to the respective one of the housing plug connectors. In
an exemplary embodiment of the compressor housing, the printed
circuit board is provided with three tracks for connecting six plug
connectors. Furthermore, the printed circuit board may be
ring-shaped and disposed coaxially with the compressor wheel and
between a volute of the compressor housing and an inlet of the
compressor housing.
[0021] In a further exemplary embodiment a turbocharger comprises
an electric motor for driving a compressor wheel accommodated in a
compressor housing, said electric motor being supplied with
electric power through at least one motor plug connector, and
further comprises a turbine housing for accommodating a turbine
wheel driven by exhaust gas, a center housing for accommodating a
shaft and the electric motor, wherein the shaft serves as a rotor
of the electric motor and extends from the turbine wheel through a
journal bearing and through the electric motor to the compressor
wheel, and wherein the compressor wheel is driven by the turbine
wheel via the shaft and can also be driven by the electric motor,
wherein said motor plug connector is disposed on an axial side of
said electric motor, facing said compressor housing.
[0022] Alternatively or additionally, the compressor housing
further comprises at least one main power plug connector
connectable to an electric power source and at least one housing
plug connector electrically connected to a respective one of the at
least one main power plug connector for supplying said electric
motor with electric power, wherein said housing plug connector is
disposed on an axial side of said compressor housing, facing said
electric motor.
[0023] Summarily, a turbocharger may comprise a compressor housing
having any of the above described features of a compressor housing,
an electric motor having any of the above described features of an
electric motor as well as any features of an above described
turbocharger. Thus, a turbocharger is provided, in which the power
supply to the electric motor takes the following path: from the
power source to the main power plug connector arranged on the
compressor housing, passing through the compressor housing by means
of the printed circuit board and then from the housing plug
connectors to the motor plug connectors attached on the axial side
of the motor, and finally to the stator of the electric motor.
[0024] Other features and advantages of the invention will become
apparently from the description that follows with reference being
made to the enclosed drawings, in which:
[0025] FIG. 1 is a sectional view of a turbocharger having an
electric motor and a compressor housing according to an exemplary
embodiment of the invention.
[0026] FIG. 2 is a sectional view of the turbocharger of FIG. 1 in
a state in which the compressor housing is not mounted to the
center housing.
[0027] FIG. 3 is a side view of an electric cartridge assembly
accommodating the electric motor and motor plug connectors and
useable with the turbocharger of FIG. 1.
[0028] FIG. 4 is a frontal view of the electric cartridge assembly
of FIG. 3 showing the arrangement of the motor plug connectors.
[0029] FIG. 5 is a sectional view of the compressor housing of FIG.
1 showing the arrangement of the main power plug connectors, the
housing plug connectors and the printed circuit board.
[0030] FIG. 6 is a rear view of the printed circuit board showing
the arrangement of the main power connectors.
[0031] FIG. 7 is a frontal view of the printed circuit board
showing the arrangement of the housing plug connectors.
[0032] FIG. 8 is several sectional views through the printed
circuit board illustrating the connection of the main power plug
connectors to the respective housing plug connectors via respective
tracks.
[0033] FIG. 9 is a schematic view of the lead wires of the printed
circuit board.
[0034] FIG. 10 is a sectional view of a turbocharger according to
the prior art, and
[0035] FIG. 11 is an enlarged portion of the electrical connection
according to the prior art shown in FIG. 10.
[0036] An electrically assisted turbocharger according to the
exemplary embodiment shown in FIG. 1 comprises a turbine housing 4
for accommodating a turbine wheel 8, a center housing 3 for
accommodating an electric motor cartridge 7 and a compressor
housing 2 for accommodating a compressor wheel 5. A shaft 6 extends
through the center housing 3 and the electric motor cartridge 7
accommodated therein so as to connect the compressor wheel 5 to the
turbine wheel 8.
[0037] Generally, the compressor wheel 5 is driven by the turbine
wheel 8 due to the exhaust gas flowing through an inlet and a
volute of the turbine housing thus driving the turbine wheel 8.
However, when the energy of the exhaust gas is low the driving of
the compressor wheel 5 is assisted by the electric motor 21 which
needs a power supply.
[0038] The electric motor 21 has a stator 9 and a rotor 10 wherein
the latter may be provided in form of the shaft 6 itself. According
to this embodiment the electric motor 21 is accommodated in an
electric motor cartridge 7 which is, as a prefabricated assembly,
slid over the shaft 6 into the center housing 3 when assembling the
turbocharger.
[0039] The electric motor cartridge 7 has a cylindrical shape and
has an axial side 24 facing the compressor housing 2. When
assembling the turbocharger 1, the compressor wheel 5 is slid over
the shaft 6 and inserted into a recessed portion 29 of the axial
side 24 of the cartridge 7. The recessed portion 29 is surrounded
by a ring projection 27 of the axial side 24. Since the compressor
wheel 5 is partly concave-shaped and is very near to the cartridge
7, the recessed portion 29 has a convex-shaped portion 25. The
motor cartridge 7 is fixed to the center housing by means of bolts
26.
[0040] Six blade-shaped male motor plug connectors 12 are disposed
on an axial side 22 of the electric motor 21 and are connected to
respective coils 23 on the stator 9. The axial side 22 of the
electric motor 21 is the side which is adjacent to the opening of
the center housing 3 into which the cartridge 7 is to be inserted.
The motor plug connectors 12 project through the ring projection 27
of the cartridge 7.
[0041] FIG. 5 shows a compressor housing assembly comprising the
compressor housing 2 and a printed circuit board 14 (PCB). The
compressor housing 2 further accommodates the compressor wheel 5 in
the compressor wheel chamber 28 and provides a compressor air inlet
20 for conveying the air from the inlet 20 through a radial air
flow path 30 to the compressor volute 15. The radial air flow path
30 is formed between the electric motor cartridge 7 and the center
housing 3, respectively, and the compressor housing 2.
[0042] Since the motor plug connectors 12 project from the axial
side of the electric motor 21 into the housing plug connectors 13
they cross the compressor air flow path 30 as can bee seen in FIG.
1. This can lead to a disturbing effect to the passing air or to a
compressor efficiency drop. To minimize this effect, the six motor
plugs 12 are blade-shaped and slanted with respect to the radial
direction of the ring projection 27. In other words, the motor
plugs are arranged such as to have a flow resistance as small as
possible. Furthermore each one of the motor plug connectors 12
corresponds to one of six phases #1 to #6 of the electric motor 21
for supplying power to the respective coils 23 (see FIGS. 3 and
4).
[0043] FIG. 6 shows a rear view of the PCB 14 on which six main
power plugs 16 are disposed, and FIG. 7 shows a frontal view of the
PCB 14 on which six housing plugs 13 are disposed. The main power
plugs 16 are arranged as male plugs in a bundle giving the
possibility to supply power to the bundled main power plugs 16
through a compact main power contra plug (not shown) connected to a
power source (not shown). Each of the main power plugs 16
corresponds to one of the phases #1 to #6.
[0044] The housing plugs 13 are arranged on the PCB 14 at radially
equal intervals and slanted corresponding to the above described
motor plugs 12. Each of the housing power plugs 13 corresponds to
one of the six phases #1 to #6. The PCB 14 is arranged such in the
compressor housing 2 that the housing plug connectors 13 open to
the side of the compressor housing 2 to be connected to the center
housing 3. Furthermore, the female housing plug connectors 13 do
not project from the compressor housing 2 but are in alignment with
the surface of the compressor housing 2 which is a part of above
described radial air flow path 30. Thus, only the male motor plug
connectors 12 are exposed to the compressed air in the radial air
flow path 30 and the female housing plug connectors 13 contribute
to a disturbance of the air flow only at a minimized level.
[0045] The supply from the bundled main power plugs 16 to the
housing plugs 13 is enabled by three tracks 17, 18 and 19 embedded
in the PCB 14. FIG. 8 shows sectional views through the PCB 14
along virtual lines crossing the housing plugs #1 and #4, housing
plugs #2 and #5 and housing plugs #3 and #6, respectively. From
these figures and the schematic FIG. 9 it can be understood, that
the main plug #4 is electrically connected to the housing plug #4
directly, the main plugs #3 and #5 are connected to the housing
plugs #3 and #5 via the first track 17, respectively, the main
plugs #2 and #6 are connected to the housing plugs #2 and #6 via
the second track 18, respectively, and that the main track #1 is
connected to the housing plug #1 via the third plug 19. Such an
arrangement allows a minimized space for the PCB and reduced short
circuit risk of the electrical connection between the plugs.
[0046] As can be seen from FIG. 1, the main power plugs 16 are
arranged with respect to the compressor housing 2 at an area where
the compressor volute 15 has a reduced dimension which provides
more space for the main power connection.
[0047] With an arrangement as described above it is possible to
easily assemble the turbocharger, as can be see from FIG. 2.
According to what is shown in FIG. 2, after sliding the electric
motor cartridge 7 and the compressor wheel 5 over the shaft 6, the
compressor housing assembly can easily be mounted on the center
housing 3. Therefore, the compressor housing 2 is attached to the
center housing 3 by plugging the female housing plug connectors 13
of the center housing 3 onto the male motor plug connectors of the
electric motor 21. Due to the plug-in of the plug connectors 12, 13
the compressor housing 2 is at least radially fixed to center
housing 3 while simultaneously creating an electrical connection of
the lead wires of the electric motor 21 to the lead wires of the
PCB 14 in the compressor housing 2. An axial fixation of the
compressor housing 2 to the center housing 3 may be established by
bolts or other fixation means.
[0048] Furthermore, with such an arrangement, the lead wires of the
electric motor do not have to be threaded each through a hole in
the center housing 3. This makes the assembly easy, eliminates the
presence of sharp edges which may contribute to short circuit risk
and there are no lead wires which need to pass the water cavity 31
of the center housing 3. Therefore, the water cavity 31 is not
affected by any lead wires and can be designed appropriate for a
good cooling performance of the electric motor 21.
[0049] The integration of the PCB in the compressor housing is
compatible with p-mold but also with die-cast one piece processes
which is advantageous in view of the production costs.
[0050] Furthermore, a single main connector can be used for power
supply and as a speed sensor, if required. This decreases the
number of elements and leads to reduced production costs.
[0051] Additionally, the invention is compatible with GT (Garrett)
and VNT (Variable Nozzle Turbine) e-Turbochargers and with
turbocharger assembly processes.
[0052] The invention is not restricted to the above described
embodiments and can be changed in various modifications.
[0053] For example, the electric motor may also be incorporated
into the center housing without being arranged in a motor
cartridge. The shape of the housing plugs and of the motor plugs
may vary in view of fluidic aspects. For example, in the above
embodiment only the male motor plugs are exposed to the air in the
radial air flow path 30 since the female housing plugs do not
project from the compressor housing 2. However, the plugs may also
be arranged such that the female housing plugs project out of the
compressor housing while providing an optimal fluidic shape and the
male motor plugs may have a shape which does not need to be optimal
in view of fluidic aspects since in this case they would not be
exposed to the compressed air.
[0054] Additionally, the shape of the plugs may be reversed such
that the motor plugs are female plugs while the housing plugs are
male plugs.
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